Researchers from UNSW Canberra have developed a new 3D-printed implant that could significantly change how fractures and bone injuries are treated, bringing personalised, biodegradable bone implants closer to clinical reality.
The implants, known as bone scaffolds, are small porous structures placed into damaged areas to support bone regrowth. Acting as a temporary framework, they allow cells to attach and rebuild tissue before safely dissolving once healing is complete, removing the need for a second surgery.
Until now, most bone scaffolds have relied on simple, repetitive internal designs that fail to reflect the complexity of real bone. The new research, led by PhD student Kaushik Raj Pyla, instead uses stochastic lattice structures – irregular, randomly patterned designs that more closely mimic bone’s natural internal architecture.
The team produced the scaffolds using polylactic acid, a biodegradable polymer commonly used in medical applications. By carefully adjusting print temperature and retraction settings, they addressed common 3D printing problems such as sagging and stringing to achieve clean, accurate structures.
“Bone can be damaged in many locations, and its structure changes depending on where it is in the body,” Kaushik said. “We wanted to see if matching these patterns could help restoration. Our idea was to take existing bone patterns and check if they could be rebuilt through printing.”
To test performance, the researchers created scaffolds with different internal grading directions, including lengthwise, crosswise and diagonal patterns, and subjected them to mechanical stress. The results showed the scaffolds performed significantly better under sudden impact than under slow compression, absorbing energy quickly and displaying different fracture behaviours depending on the design.
“Under fast loads, the material acts more brittle, but it also absorbs energy more efficiently. This is important for real-world scenarios like falls or accidents,” Kaushik explained.
The team also examined fluid permeability, a critical factor in healing, as blood and nutrients must flow through the scaffold to support cell growth. Certain designs showed strong performance in both mechanical strength and fluid flow.
“We found that certain designs performed especially well in both strength and fluid flow. This suggests that implants can be tailored depending on the stresses different bones experience,” Kaushik said. “And with 3D printing, scaffolds can be customised to match the patient and injury.”
The research comes amid growing concern about bone health, particularly in the ACT, where more than 98,000 people are affected by poor bone health. In 2025, the territory is expected to record more than 2900 fractures, with direct healthcare costs exceeding $73 million, according to Healthy Bones Australia.
“These figures highlight the growing burden of osteoporosis and fracture-related injuries – and the importance of developing safer, more effective treatments like the 3D-printed bone scaffolds,” Kaushik said.
While further biological testing, long-term studies and regulatory approvals are required, the researchers are optimistic about future applications, including cartilage and soft tissue scaffolds, with early clinical testing anticipated within five years.
“Biodegradable scaffolds will likely play a key role in reducing both medical risks and overall treatment costs,” Kaushik said. “We’re moving toward safer, more personalised implants that work with the body, not just in it.”
Author – Libby Moorhead
